Reinforced structural member and frame structures

ABSTRACT

Disclosed are frame members and mullions for a window frame that comprise a reinforcing member that is surrounded by an outer plastic layer. The outer plastic layer is held securely to the reinforcing member as a result of a waist banding effect that comprises an inward force created by the outer plastic layer as it cools and contracts around the reinforcing member. In addition, lobes are formed in the reinforcing member that assist in holding the outer plastic layer to the reinforcing member. Window inserts can be removed and replaced using adapters and removable brackets. Frame members and mullions can be built sufficiently strong to provide structural support. The frame can also be used to hold photovoltaic cells and protective coverings for photovoltaic cells. Structural members are also disclosed that have reinforcing members with apertures, debossing, scarification and/or indentations that secure the thermoplastic layer to the reinforcing member.

CROSS REFERENCE TO RELATED APPLICATION

This application is a divisional application of U.S. patent applicationSer. No. 13/585,529, filed Aug. 14, 2012, which application is adivisional application of U.S. patent application Ser. No. 12/253,155,filed Oct. 16, 2008, which application is based upon and claims thebenefit of U.S. Provisional Application No. 60/980,423, filed Oct. 16,2007, and U.S. Provisional Application No. 60/980,427, filed Oct. 16,2007. U.S. patent application Ser. No. 12/253,155 is also acontinuation-in-part application of U.S. patent application Ser. No.11/777,930, filed Jul. 13, 2007, (now U.S. Pat. No. 7,721,496 issued May25, 2010), which application is a continuation-in-part application ofU.S. patent application Ser. No. 11/675,587, filed Feb. 15, 2007 (nowU.S. Pat. No. 7,930,866 issued Apr. 26, 2011), which is acontinuation-in-part application of U.S. patent application Ser. No.11/194,973, filed Aug. 2, 2005 (now U.S. Pat. No. 7,213,379 issued May8, 2007), which claimed the benefit of U.S. Provisional Application No.60/598,014, filed Aug. 2, 2004, U.S. Provisional Application No.60/644,451, filed Jan. 14, 2005, and U.S. Provisional Application No.60/686,870, filed Jun. 1, 2005. In addition, U.S. patent applicationSer. No. 11/675,587, filed Feb. 15, 2007 (now U.S. Pat. No. 7,930,866issued Apr. 26, 2011), claimed the benefit of U.S. ProvisionalApplication No. 60/774,105, filed Feb. 15, 2006, U.S. ProvisionalApplication No. 60/791,301, filed Apr. 12, 2006, and U.S. ProvisionalApplication No. 60/822,048, filed Aug. 10, 2006. In addition, U.S.patent application Ser. No. 11/777,930 (now U.S. Pat. No. 7,721,496issued May 25, 2010) also claimed the benefit of U.S. ProvisionalApplication No. 60/807,294, filed Jul. 13, 2006. U.S. patent applicationSer. No. 12/253,155 is also a continuation-in-part application of U.S.patent application Ser. No. 11/696,629, filed Apr. 4, 2007 (now U.S.Pat. No. 7,882,679 issued Feb. 8, 2011), which application is acontinuation of U.S. patent application Ser. No. 11/194,973 (now U.S.Pat. No. 7,213,379 issued May 8, 2007) (which claims the benefit ofother applications listed above). U.S. patent application Ser. No.12/253,155 is also a continuation-in-part application of U.S. patentapplication Ser. No. 12/233,523, filed Sep. 18, 2008 (now U.S. Pat. No.8,065,848 issued Nov. 29, 2011), which application claimed the benefitof U.S. Provisional Application No. 60/973,425, filed Sep. 18, 2007. Theentire disclosures of all of these applications are specificallyincorporated herein by reference for all that they disclose and teach.

BACKGROUND OF THE INVENTION

Use of engineered materials, such as wood composites and variousplastics, including recyclable thermoplastic, such as high-densitypolyethylene (HDPE), is becoming increasingly popular in theconstruction industry. These uses encompass various horizontal andvertical applications that meet a range of present decorative and/orstructural construction needs.

Structural members, such as joists, beams and the like, are currentlyavailable as wood lumber, a valuable yet limited resource with norecycling capability, as plastic lumber, and as reinforced or compositelumber. Composites often include wood fiber or fiberglass in a plasticmatrix, or wood composites such as I-joist products.

SUMMARY OF THE INVENTION

An embodiment of the present invention may therefore comprise a framestructure comprising: a reinforcing member having an outer surface andat least a portion having a substantially hollow interior, a pluralityof lobes formed in the reinforcing member that have an interior lobethat is larger than a waist opening; a first plastic layer that isextruded into the lobes and extends into the waist opening; an exteriorplastic layer that is extruded over substantially all of the outersurface of the reinforcing member while the first plastic layer issufficiently hot to knit the exterior plastic layer to the first plasticlayer to form a substantially unitary plastic coating structurecomprising the first plastic layer and the exterior plastic layer thatis held securely to the reinforcing member by the first plastic layerthat is disposed in the lobes, the exterior plastic layer creating aninward force on the reinforcing member as the exterior plastic layercools and contracts to further hold the exterior plastic layer securelyto the reinforcing member; a recess formed in the reinforcing memberthat is covered by the substantially unitary plastic coating structurethat secures an insert to the frame structure.

An embodiment of the present invention may further comprise a framestructure comprising: a reinforcing member having an outer surface andat least a portion that has a substantially hollow interior, a pluralityof lobes formed in the reinforcing member that have an interior lobedimension that is larger than a lobe waist opening; a first plasticlayer that is extruded into the lobes and extends into the lobe waistopening; an exterior plastic layer that is extruded over substantiallyall of the outer surface of the metal reinforcing member while the firstplastic layer is sufficiently hot to knit the exterior plastic layer tothe first plastic layer to form a substantially unitary plastic coatingstructure comprising the first plastic layer and the exterior plasticlayer that is held securely to the reinforcing member by the firstplastic layer that is disposed in the lobes, the exterior plastic layercreating an inward force on the reinforcing member as the exteriorplastic layer cools and contracts to further hold the exterior plasticlayer securely to the reinforcing member; a recess formed in thereinforcing member that is covered by the substantially unitary plasticcoating structure that secures an insert to the frame member; aremovable bracket that is attached to the support structure thatsupports the insert and allows the insert to be removed from the framestructure whenever the removable bracket is removed from the reinforcingmember.

An embodiment of the present invention may further comprise a method ofmaking a frame structure comprising: providing a reinforcing memberhaving an outer surface and at least a portion having a substantiallyhollow interior; forming a plurality of lobes in the reinforcing memberhaving an interior lobe size that is larger than a lobe waist opening;extruding a first plastic layer into the plurality of lobes until theplastic extends into the lobe waist opening; extruding an exteriorplastic layer over substantially all of the outer surface of thereinforcing member while the first plastic layer is sufficiently hot toknit to the exterior plastic layer to form a substantially unitaryplastic coating structure comprising the first plastic layer and theexterior plastic layer that is securely held to the reinforcing memberby the first plastic layer that is disposed in the lobes, the exteriorplastic layer creating an inward force on the reinforcing member as theexterior plastic layer cools and contracts to further hold the exteriorplastic layer securely to the reinforcing member.

An embodiment of the present invention may further comprise a method offorming a structural member comprising: providing a reinforcing memberthat has a predetermined shape, the reinforcing member providingstructural rigidity to the structural member; working at least a portionof the reinforcing member to form worked portions of the reinforcedmember; passing the reinforced member through a crosshead die extruderthat utilizes crosshead dies; extruding a thermoplastic using thecrosshead die extruder over an outer surface of the reinforcing memberat a temperature within a predetermined temperature range so that thethermoplastic adheres to the worked portions of the reinforcing memberto form the structural member.

An embodiment of the present invention may further comprise a structuralmember comprising: a reinforcing member that forms a structural supportfor the structural member, the reinforcing member having a predeterminedshape and worked portions; a thermoplastic layer that is extruded overat least a portion of the reinforcing member using a crosshead dieextruder at a temperature in a predetermined temperature range to causea thermoplastic material, that has a viscosity that is sufficiently low,to engage and adhere to the worked portions of the reinforcing member.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a perspective view of a thermoplastic structural memberaccording to one embodiment of the invention, configured as a post forsupporting additional structural members such as a beam.

FIG. 2 shows a perspective view of the thermoplastic structural memberof FIG. 1.

FIG. 3 shows an end-on view of the thermoplastic structural member ofFIG. 1, depicting a series of reinforcing cross-supports in oneembodiment of the present invention.

FIG. 4 shows an end-on view of the thermoplastic structural member ofFIG. 1, according to another embodiment of the present invention.

FIG. 5 shows an end-on view of a thermoplastic structural member inanother embodiment of the present invention.

FIG. 6 shows an end-on view of a thermoplastic structural member inanother embodiment of the present invention.

FIG. 7 shows an end-on view of a thermoplastic structural member inanother embodiment of the present invention.

FIG. 8 shows an end-on view of a thermoplastic structural member inanother embodiment of the present invention.

FIG. 9 shows an end-on view of the thermoplastic structural member inanother embodiment of the present invention.

FIG. 10 shows an end-on view of the thermoplastic structural member inanother embodiment of the present invention.

FIG. 11 shows an end-on view of the thermoplastic structural member inanother embodiment of the present invention.

FIG. 12 shows an end-on view of the thermoplastic structural memberaccording to one embodiment of the present invention, showing a pair ofbolts connected therein.

FIG. 13 shows an end-on view of the thermoplastic structural memberaccording to one embodiment of the present invention, showing a pair ofbolts connected therein.

FIG. 14 shows a detailed view of a portion of the thermoplasticstructural member according to one embodiment of the present invention.The drawings are not necessarily to scale.

FIG. 15A is a schematic side view of an embodiment of a window frame.

FIG. 15B is a schematic illustration of an embodiment of a window framewith an attached header.

FIG. 15C is a schematic illustration of another embodiment of a windowframe.

FIG. 16 is a schematic illustration of frame connectors that are used tojoin frame members.

FIG. 17 is a schematic top view of a frame member for a window.

FIG. 18 is a schematic top view of an embodiment of a frame member.

FIG. 19 is a schematic top view of an embodiment of a mullion.

FIG. 20 is a schematic top view of another embodiment of a mullion.

FIG. 21 is a schematic top view of another embodiment of a mullion.

FIG. 22 is a schematic top view of another embodiment of a mullion.

FIG. 23 is a schematic top view of another embodiment of a mullion.

FIG. 24 is a schematic top view of another embodiment of a frame member.

FIG. 25 is a schematic top view of another embodiment of a frame member.

FIG. 26 is a schematic top view of another embodiment of a frame member.

FIG. 27 is a schematic top view of another embodiment of a frame member.

FIG. 28 is a schematic diagram of an embodiment of a two-stage crossheaddie.

FIGS. 29-47 illustrate various embodiments of structural members.

FIG. 48 is a schematic perspective view of a debossing device.

FIG. 49 is a schematic perspective view of a scarification device.

FIG. 50 is a flow diagram of one embodiment of a process for forming astructural member.

FIG. 51 is a schematic block diagram of another embodiment of a processfor forming a structural member.

DETAILED DESCRIPTION OF THE EMBODIMENTS

FIG. 1 discloses a load bearing assembly 10 that includes a pair ofstructural members 20 shown supporting decking 22, and furthersupporting a beam 14 attached to structural member 20 by screws 18. Asdiscussed in further detail below, these structural members 20 shown inFIG. 1 as posts, are comprised of an interior reinforcing member, whichextends longitudinally through the structural member, and are furthercomprised of a thermoplastic outer layer or casing. Structural member 20is thus protected from outside elements such as rain, snow and exposureto other corrosive materials by way of the thermoplastic casingsurrounding the interior reinforcing member.

In accordance with the various embodiments disclosed, the interiorreinforcing member may comprise a variety of materials. Moreparticularly, and by way of example and not limitation, the reinforcingmember may be made of metal or a metal alloy, including aluminum, oraluminum alloy, steel, or stainless steel. Alternatively, thereinforcing member may comprise carbon fiber, glass-reinforcedpolyurethane, and/or fiberglass. In addition, a combination of one ormore of the previously listed materials may be used to make the interiorreinforcing member.

Reinforced structural members are designed to withstand varying modes ofdeformation and failure. Structural members such as columns or postsoften fail in direct compression, but may also buckle by bending ordeflecting laterally due to stress on the member. As the buckling stressincreases, the lateral deflection will increase and eventually thecolumn will collapse. Individual components within the column, such asreinforcing members or the walls of a hollow columnar cross member, mayexperience local buckling or wrinkling under these stresses.

Cross members such as posts or columns are designed to support acritical load. The critical load for an ideal elastic column is oftenreferred to as the Euler load. The critical load of a column isproportional to the flexural rigidity and inversely proportional to thesquare of the length of the column. The strength of the material itselfdoes not necessarily affect the critical load; however, the load can beincreased by using a stiffer material (a material with a larger modulusof elasticity). Also, the load may be increased by distributing thematerial in such a way as to increase the moment of inertia about thecross-section of area. The moment of inertia may be increased bydistributing the material away from the centroid of the cross-section ofthe cross member. Hollow tubular members are more economical for columnsthan are solid members having the same cross-sectional areas. This isdue in part to the fact that hollow sections are more efficient thansolid sections because they provide a larger moment of inertia for thesame cross-sectional area. For this reason, increasingly the design ofposts and columns incorporates either a hollow rectangular or circularcross-section, which may further include a variety of reinforcing crossmembers contained therein.

For a hollow member, reducing the wall thickness and increasing thelateral dimension, while keeping the cross-sectional area constant,tends to increase the critical load as the moment of inertia isincreased. This has a practical limit, however, because eventually thewall itself will become unstable, and as localized buckling occurs smallwrinkles will occur on the surface of the columnar member. If thecross-section of the support is square or circular, all centroidal axeshave the same moment of inertia, and therefore buckling may occur in anylongitudinal plane. Therefore, the symmetry of the column, and thesymmetry of the reinforcing members contained therein, has an importantrole in designing and accounting for the critical load and therebypreventing any buckling or deformation of the structural member.

The interior reinforcing members are configured such that additionalcross members may be attached thereto, as shown in FIG. 1 as beam 14.Attachments of additional structural members may take several forms, forexample, but not by limitation, by screws, nails, bolts, rivets, orother fastening mechanisms or attachment means for coupling two or moremembers together. In the exemplary configuration shown in FIG. 1, thestructural members 20 may not only support lateral or transverse loads,but may also support loads in compression, such as by supporting decking22 or another type of platform or structure. In this manner, structuralmember 20 may serve as a column, post or pier for providing load-bearingsupport of additional members.

Embodiments include structural members formed with a resin, such as athermoplastic. Various types of thermoplastic may be used. In at leastone embodiment of the present invention, structural members compriseHDPE and a reinforcing member that acts as a strengthened interior forthe HDPE. The HDPE is preferably without cellular fiber content, such aswood fiber, and at least to the extent that any such content should notseriously impact resistance to moisture of the resulting structuralmember. Also, the HDPE is without fiberglass to the extent that theability of the structural member can remain easily cut and/or drilledwithout tool damage. However, unless otherwise specified, anythermoplastic and/or thermoplastic composite materials are collectivelyherein referred to as simply “HDPE” or “thermoplastic,” and it is to beunderstood that reference herein to “HDPE” and “thermoplastic” includesother possible thermoplastics other than HDPE, such as, but not limitedto, polypropylene (PP), as well as blends, composite/amendedthermoplastic materials, and/or coated thermoplastic members, andfurther includes substantially virgin or recycled HDPE. Furthermore,other materials other than thermoplastics are within the scope of theinvention, including polyvinyl chloride. Thus, a structural member, suchas a column or post that utilizes a non-thermoplastic (non-HDPE)material to form its outer casing is within the scope of the presentinvention.

FIG. 2 discloses a structural member 20 in a perspective view.Structural member 20 is comprised of component parts, some of whichextend from a first end 23 to a second end 25 of structural member 20,such that the component parts may be said to extend the longitudinallength L of the structural member. In this manner, structural member 20may serve as a column, post or pier for providing load-bearing supportof additional members, or may serve as a beam to support transverseloads.

FIG. 3 discloses a structural member 20 in an end-on view. Structuralmember 20 is comprised of an interior reinforcing member 26, which iscontinuous throughout the longitudinal length L of the structural member20, and may be configured in varying embodiments to providereinforcement of structural member 20 to prevent crushing, bending,buckling, wrinkling, or other deformation. According to one embodiment,structural member 20 has a reinforcing member 26 in a symmetricalpattern that includes channels 28 which extend inwardly towards thecenter of structural member 20 and which further define lobes about theexterior of the structural member. As discussed below with reference toFIG. 14, the channels 28, according to one embodiment, are formed assaddle portions of recessed areas in the exterior surface of thereinforcing member 26 such that the saddle portions comprise a narrowedor tapered neck section and then gradually taper outwards to a largercross-sectional diameter, thus creating a lobe, which has severaldesirable benefits. First, the channels 28 are provided to secure thethermoplastic casing 24 and hold the thermoplastic casing 24 in placeafter the casing material has been formed around the reinforcing member26 and has fully cooled. As appreciated by one of ordinary skill in theart, thermoplastic and thermosetting materials are subject todeformation during manufacture and transport. In addition, thesematerials are further subject to expansion and contraction due tofluctuations in temperature. The channels 28 formed along the exterior34 of the reinforcing member 26 allow the thermoplastic casing 24 to belocated within a portion of the channel 28 such that it becomes securelyengaged with the reinforcing member 26 despite possibly undergoingfuture expansion and/or contraction. This is achieved by having a largerdiameter in the lobe section of the channels 28 than the diameter of theneck or waist section of the channels 28, as described in greater detailwith regard to FIG. 14 below.

Channels 28 also provide multiple surfaces along the interior 40 of thereinforcing member 26 for connecting cross members 36 within theinterior 40 of reinforcing member 26. As shown in FIG. 3, multiple crossmembers 36 are shown connecting adjacent pairs of channels 28 to form agenerally octagonal pattern 38. Thus, the channels 28 provide multiplelocations for connecting internal cross members 36. The interiorsurfaces 30 of the channels 28 extend inwardly toward interior 40 andtherefore provide convenient points for connecting cross members 36within the interior 40 of the reinforcing member 26, to increase thecritical load of structural member 20, and thereby prevent crushing,buckling, warping, wrinkling, or other deformations. In variousembodiments, the cross members 36 may be arranged between the interiorsurfaces of channels 28 such as to improve the support from one side ofthe reinforcing member 26 to another side, so as to prevent deformationbetween those two sides of the reinforcing member 26. In otherconfigurations, the arrangement of cross members 36 within the interior40 of the structural member 20 may prevent additional deformations ormodes of failure such as by torsional and/or shear forces.

Reinforcing member 26 is encased by thermoplastic casing 24 andpreferably includes a metal, such as steel, aluminum or an aluminumalloy, or alternatively, the reinforcing member may comprise carbonfiber, glass-reinforced polyurethane, and/or fiberglass. In accordancewith several embodiments of the present invention, interior 40 ispreferably hollow. That is, the central interior area 42 and peripheralinterior areas 44 may be hollow. Alternatively, one or more cells orinterior areas 42 and 44 of the interior 40 may be filed with adifferent material such as, by way of example and not limitation, athermoplastic, foam, concrete and/or earthen material. Such optionalfilling of the interior areas of the reinforcing members applies to allembodiments described herein. Reinforcing member 26 and cross members 36preferably extend the entire longitudinal length L of structural member20.

In accordance with embodiments of the present invention, cross members36 may further include a thermoplastic material casing (not shown inFIG. 3) for providing additional protection and/or support to structuralmember 20. In at least one embodiment, such material preferablycomprises HDPE. Surficial features such as divots and other texturing,such as scarification, may be provided. Various embodiments may notrequire surficial feature for certain types of plastic material, such asglass-reinforced polyurethane, because sufficient chemical bondingbetween the material types is provided. Where appropriate, divots,scarification, or other surficial features assist in limiting orremoving sliding tendencies between the HDPE and cross members 36 whenstructural member 20 is under loaded conditions. In an alternativeembodiment, the cross members 36 may include apertures along theirlongitudinal length that act as openings for receiving at least someHDPE when the HDPE is introduced around the cross members 36

The presence of interior cross members 36 improves the structuralperformance of the structural member 20, and allows the structuralmember 20 to provide adequate load carrying capacity with tolerabledeflection, while maintaining a relatively small profile. Preferably,the reinforcing member 26 and cross members 36 include a metal or metalalloy, as for example, an aluminum alloy, with the dimensions andthickness of the reinforcing member 26 and cross members 36 capable ofbeing customized and selected based on intended use of the structuralmember 20. The reinforcing member 26 and cross members 36 may alsoinclude or comprise carbon fiber, glass-reinforced polyurethane and/orfiberglass. The use of an aluminum alloy material as compared to steelfor the reinforcing member 26 can enable a lighter weight structuralmember 20 and can enable the structural member 20 to be cut relativelyeasily using standard construction equipment. That is, an aluminum alloyprovides attractive reinforcing characteristics, while at the same timenot unduly dulling cutting blades of saws that are used to dimension tolength the structural member 20. Carbon fiber provides yet a lighterweight structural member 20, but would potentially require the use ofdiamond-bit blades for successful repeated cutting and dimensioning thestructural member 20. Glass-reinforced polyurethane provides anotheroption for the reinforcing material, as does fiberglass.

FIG. 4 discloses another configuration for the cross members 66. Thecross members 66 of FIG. 4 extend diagonally from an intermediate point68 along each of the four faces 62 of the reinforcing member 56, so asto form a generally diamond-shaped pattern in a cross-sectional view ofthe structural member 50. For the embodiment shown in FIG. 4, the crossmember angle Θ formed between the cross members 66 is preferably betweenabout 30 and 150 degrees, and more preferably, between about 60 and 120degrees, and/or more preferably yet, about 90 degrees. The actual crossmember angle Θ that is used may vary depending upon the shape of thestructural member, the reinforcing member, and the interior crossmembers. For the embodiment shown in FIG. 4, this configuration providesadditional structural support for loads in compression, as well as loadsin the lateral direction, including but not limited to loads created byattaching additional structural members to the structural member 50 byway of a screw, a nail, a bolt, or other attachment means which extendlaterally through the structural member 50.

The various configurations of the reinforcing member 56 comprising aplurality of cross members 66 enhances the strength of the entirestructural member 50. This is achieved under loading conditions when thepattern of cross members 66 tends to provide a secondary column orreinforcing member within reinforcing member 56. Likewise, the channels58 are coupled to the HDPE and thereby further reinforce the structuralmember 50 under loading conditions. In addition, the channels 58 keepthe HDPE from traversing along the longitudinal axis of the reinforcingmember 56 when under loading conditions. The interior 52 of reinforcingmember 56 includes central interior area 60 and peripheral interiorareas 64.

FIG. 5 discloses another pattern for arranging the cross members 86within the interior of the structural member 70 for preventingdeformation of the reinforcing member 76. In this embodiment, the crossmembers 86 extend from an intermediate point 88 of each of the foursides 82 of the reinforcing member 76 and are joined in the center 80 ofthe structural member 70 to make a generally cross shaped pattern asshown in FIG. 5. The interior 72 of reinforcing member 76 includesperipheral interior areas 84.

FIG. 6 discloses another pattern for arranging the cross members 106,108 within the interior 92 of the reinforcing member 96 of structuralmember 90. In the embodiment of FIG. 6, a pattern similar to that shownin FIG. 3 is further reinforced by additional cross members 108attaching two channels 98 paired on each lateral side 100 of thereinforcing member 96, forming a total of eight individual interiorcross members 106, 108 to provide further reinforcement of thestructural member 90. Additional peripheral interior areas 102, 104 arealso formed by this pattern, which in a preferred embodiment are hollow,but may be filled with a foam or other material as desired.

FIG. 7 discloses another embodiment comprising two additional crossmembers 114 from those described in relation to FIG. 6. Two crossmembers 114 extend from an intermediate portion of the diagonal crossmembers 106 on each corner of the reinforcing member 96 and extendtowards the center 118 of the structural member 90 as shown in FIG. 7.This forms a generally “X”-shaped pattern for providing additionalsupport and reinforcement to prevent bending and/or buckling.

FIG. 8 discloses another embodiment in which the pattern for arrangingcross members 106, 108, 122 within the structural member 90 is orientedto connect two interior cross members 122 to four of the cross members108 adjacent each side 100, forming a generally cross-shaped pattern asshown in FIG. 8. In this embodiment, the support pattern as shown inFIG. 6 is combined with the pattern of FIG. 5 to form additionalreinforcement of the reinforcing member.

FIG. 9 discloses another embodiment depicting configurations forinterior cross members 142, 146. According to this embodiment, crossmembers 142, 146 are arranged primarily in a single planar directionextending from one lateral face 148 of the reinforcing member 136 toanother face 148 of the reinforcing member 136, and also between two ofthe interior surfaces 30 of the channels 138 paired along the remainingface 148 of the reinforcing member 136, so as to provide support in thatlateral direction. Thus, the configuration of cross members 142, 146 asdepicted in FIG. 9 accommodates insertion of a bolt or other attachmentmeans to prevent bending, crushing, or buckling of the reinforcingmember 136 in the lateral direction perpendicular to the direction thecross members 142, 146 are oriented within the structural member 130.

FIG. 10 discloses another embodiment depicting configurations forinterior cross members 196. According to this embodiment, cross members196 are arranged extending from an interior surface 30 of each channel192 of the reinforcing member 188 to form a generally triangle shapedcross support configuration within the interior of the reinforcingmember 188 so as to provide support in that lateral direction. In oneembodiment, the generally triangle shape is substantially in the shapeof an equilateral triangle, as is the shape of the structural member180. Peripheral interior areas 198 are formed surrounding a centralinterior area 202, which in a preferred embodiment are hollow, but maybe filled with a foam or other material as desired.

FIG. 11 discloses another embodiment comprising two cross members 226extending from the interior surface 30 of one channel 222 to an interiorsurface 30 of an opposite channel 222. Two cross members 226 extendthrough the center of the structural member 210 as shown in FIG. 11.This forms a generally “X”-shaped pattern for providing additionalsupport and reinforcement to prevent bending and/or buckling. Thisfurther creates four independent peripheral interior areas 228, whichare hollow, but may be filled with a foam or other material as desired.This circular structural member 210 also comprises a reinforcing member218 encased in a thermoplastic casing 214, and may be sized to replacecommonly specified cylindrical support elements for supportingload-bearing members.

FIG. 12 discloses a thermoplastic structural member 130 with two bolts164 extending through the interior of the thermoplastic structuralmember 130 and attached by nuts 168 on the opposite side to accommodateattachment of an additional cross member 172, such as a beam 172. In theembodiment of FIG. 12, the cross members 146 provide additional pointsof attachment for the bolts 164, and further provide reinforcementagainst bending, crushing, buckling or other deformation caused by theattachment of the bolts 164 to the walls of the structural member 130.

FIG. 13 discloses another configuration for attaching two bolts 164 tothe structural member 20. Bolts 164 are aligned spaced apart or offsetin the longitudinal direction (into the page of FIG. 10) so as to allowattachment of multiple cross members 172 on two of the four lateralfaces of the structural member 20. According to the embodiment of FIG.13, the diagonally placed cross members 36 extend in the four corners ofthe reinforcing member 26, thus providing reinforcing support to preventbending and/or buckling of the structural member caused by attachmentand tightening of the bolts 164 to the structural member 20.

The structural member and its component parts may be provided instandard sizes to accommodate substitution with existing structuralmembers. For example, structural member may generally be in the shape ofa square, which, including the HDPE casing, measures approximately 5.5inches by 5.5 inches. The HDPE measures approximately 0.250 inches inthickness around the reinforcing member, thereby making the dimensionsof reinforcing member in a preferred embodiment 5.0 inches by 5.0inches. The thickness of the extruded reinforcing member isapproximately 0.06 inches, and similarly the thickness of cross membersare also 0.06 inches. In another example where two channels are formedon each lateral side, the two channels are spaced at approximately 2.174inches on center. The distance between the facing surfaces of twochannels is approximately 1.722 inches, and the distance between theopposite face and the corner of the reinforcing member is approximately1.187 inches. Additional dimensions for the structural member aredescribed in relation to FIG. 14 in greater detail below.

As one skilled in the art will appreciate, the values described are oneexample of dimensions that may be used and are not intended to belimiting. The shapes, thicknesses and dimensions of the various featuresof the reinforcing member and surrounding HDPE are provided by way ofexample, and such dimensions allow for the reinforcing member to deflectunder loading, thereby confining the HDPE or other thermoplasticmaterial surrounding the reinforcing members. However, other dimensionsand shapes are possible and are within the scope of the presentinvention. For example, cross-sectional shapes for structural crossmembers such as circles, triangles, including equilateral triangles,rectangles, octagons (and other polygons), and other shapes bothsymmetrical and non-symmetrical are contemplated for use in the presentinvention. Thus, it is to be understood that the dimensions given hereinare for purposes of enablement, and as one skilled in the art willappreciate, other dimensions are possible. Thus, other dimensions forelements of the present invention are encompassed by the scope of theclaims.

FIG. 14 discloses additional dimensions for a structural member in apartial detailed view of structural member 20. As described above, thethickness 228 of reinforcing member is approximately 0.06 inches. Thethickness 232 of the outer thermoplastic is approximately 0.25 inches.The distance between the corner of reinforcing member and the near faceof channel 240 is approximately 1.187 inches. In addition to thesedimensions, FIG. 11 shows additional dimensions of the structural memberdepicted in FIG. 10. Those dimensions include a distance between theneck of the channel 224, and the distance between the lobe of thechannel 220. In one embodiment, the neck 224 measures approximately0.226 inches, and the lobe 220 measures approximately 0.332 inchesacross. The approximate length of cross member 212 is approximately1.525 inches, and the distance between the two adjacent channels alongthis direction 216 is approximately 1.043 inches. The radius 236 ofchannel 220 is approximately 0.166 inches, forming a nearly uniformsemi-circular area within the lobe or channel formed along reinforcingmember. The values described in this paragraph are but one example ofdimensions that may be used, and are not intended to be limiting.

During manufacture of the reinforcing members, or prior or duringforming a structural cross member such as a column, post, or beam, thereinforcing member may be textured to provide improved adhesion betweenthe surface of the reinforcing member and the outer thermoplastic.Surface texturing is anticipated to provide better bonding between thethermoplastic material and the reinforcing member, and thus betterstructural performance.

Embodiments include variety of configurations. By way of example and notlimitation, reinforcing members of the various embodiments describedherein may comprise a hollow configuration as described above asinterior, center interior area, and/or peripheral interior areas. Otherembodiments may comprise a first material forming the reinforcingmember, with a second material filling the first material. For example,the reinforcing member may comprise a hollow aluminum reinforcingmember, or the reinforcing member may be filled with another material,such as foam. In at least one embodiment, the reinforcing member maycomprise a hollow (or substantially hollow) glass-reinforcedpolyurethane structure. In at least one embodiment, the reinforcingmember may comprise a hollow foamed or unfoamed glass-reinforcedpolyurethane material. In at least one embodiment, the reinforcingmember may comprise a solid (or substantially solid) member, such as afoamed or an unfoamed glass-reinforced polyurethane material. Thereinforcing members may also comprise a metal, a metal alloy, steel,aluminum, an aluminum alloy, glass-reinforced polyurethane, carbonfiber, foamed and unfoamed glass-reinforced polyurethane, fiberglass,and combinations thereof.

In accordance with various embodiments, where the structural member iscomprised of a composite glass-plastic reinforcing member, a member mayfurther comprise a continuous liquid glass (CLG) and polyurethanematerial. The CLG material has a liquid-like viscosity upon extrusionduring the manufacturing process, but hardens as it cools. In at leastone embodiment, the CLG and polyurethane material is foamed duringmanufacture. In at least one embodiment, the CLG and polyurethanematerial is not foamed during manufacture. In accordance with variousembodiments, the composite glass-plastic reinforcing member forms achemical bond when co-extruded with the surrounding thermoplasticmaterial so that reinforcing member remains integrally secured to thesurrounding thermoplastic material, even under loading conditions. Inaccordance with the various embodiments, the thermoplastic materialsurrounding the reinforcing member(s) comprises a polypropylene (PP),wherein the PP may further comprise one or more fillers such as calciumcarbonate and/or talc. Talc can e included in amounts of up to 50%, butpreferably up to 40%, to add strength to the plastic material. Whenco-extruded, the thermoplastic structural member with the CLGpolyurethane core/reinforcing member demonstrates attractive engineeringproperties, such as a significant modulus of elasticity.

In accordance with various embodiments, the reinforcing member maycomprise one or more features for promoting the mechanical bonding orcoupling of the thermoplastic material to the material of thereinforcing member. Thus, in at least one embodiment, the thermoplasticis extruded around the reinforcing member, wherein no adhesives or tapeare used to facilitate bonding between the thermoplastic and thereinforcing member, which may comprise an variety of materials, such ascarbon fiber, glass-reinforced polyurethane, aluminum or a metal alloy,such as an aluminum alloy. For the reinforcing member, scarification orindentations may be provided along its longitudinal length. Theindentations of reinforcing member may provide for mechanical bondingbetween the thermoplastic and the reinforcing member. In accordance withat least one embodiment of the present invention, the indentations maybe spaced apart along the longitudinal length of the reinforcing member.

In general, the configuration of the reinforcing member with channelsacts to interlock the thermoplastic to the reinforcing member when notloaded, and further acts to allow the reinforcing member to pinch on thethermoplastic when under load, thereby making the combined materialscollectively stronger than the two independently. This provides formechanical bonding. In addition, in accordance with various embodiments,the horizontal and added vertical bonding of the two materials is alsoachieved by providing indentations or scarification of one or moresurfaces of the reinforcing member, thereby allowing the thermoplasticto enter the indentations and/or scarifications during extrusion, andsubsequently harden to mechanically bond the two together. Adhesives andother materials may also be used if necessary, although such use isoptional and depends upon the particular characteristics and intendeduse of the structural member being considered. That is, the use ofadhesives and other materials is not necessarily required or evenpreferred, however, their use in various embodiments of the presentinvention is not necessarily precluded either.

One method of manufacturing the reinforcing members comprises debossingat least a portion the reinforcing member to form the indentations.Debossing is the process of causing a depression in an object, such asforming a depressed shape below the normal surface of a material.Alternatively, the reinforcing members may be subjected to a processknown as coining to provide surficial features along at least a portionof the longitudinal length of the reinforcing members. Coining is thesqueezing of metal while it is confined in a closed set of dies.Therefore, in accordance with various embodiments, the reinforcingmember includes indentations that are spaced apart along thelongitudinal length of the reinforcing member, wherein the indentationsare caused by applying a force to the exterior of the reinforcingmember.

The columns, piers, or pylons have particular application to use inlarge structures, including bridge structures or pier supports.Depending upon the use, the hollow center area may be filled with avariety of materials, including by way of example and not limitation,water, reinforcing supports extending from one interior surface toanother, concrete, reinforced concrete, aggregate and/or other earthenmaterials such as sand, rock or rip rap.

Combining a thermoplastic with a metal alloy, such as an aluminum alloy,or steel, or carbon fiber, or glass-reinforced polyurethane in theconfigurations shown and described herein provides functionality byincreasing loading strength. Under compression or tension, the integralconfiguration of the structural members serves to resist movement fromeither, thereby improving load ratings. Hollow cores/reinforcing membersenable achieving structurally sound members with some reduction ofweight.

In accordance with various embodiments, at least one method ofmanufacture is also provided, the method comprising a unique process. Asone example, the method of manufacture may comprise a dual extrusionin-line fabrication process. It will be appreciated that the variousstructural assemblies are described herein which generally may bereferred to as structural members or load members, and are preferablyformed in a sequence of separate steps.

In accordance with another embodiment, an illustrative method ofmanufacturing a structural cross member having a rated deflectionloading includes: (a) preparing a reinforcing member of at least lengthL for bonded integration into a structural member of at least length L;(b) forming a structural support preform by feeding the reinforcingmember into a thermoplastic extruder and extruding the structural memberwith a thermoplastic, wherein the thermoplastic is bonded to the surfaceof the reinforcing member along the length of at least L; and (c)controlledly cooling the extrusion-formed structural member preformwherein the thermoplastic is bonded to the reinforcing member along thelength of at least L and wherein the bonded thermoplastic andreinforcing member share the loading of the structural member withoutseparating along the at least length L when the structural member isloaded at or below critical.

In accordance with at least one embodiment, at least portions of thethermoplastic outer layer may comprise a foaming agent. By way ofexample and not limitation, such lighter-weight material comprises athermofoamed thermoplastic with an elastomer. The foaming is provided byfoaming agents, or otherwise by microspheres that include a polymershell encapsulating glass. Thus, as those skilled in the art willappreciate, a variety of foaming agents exist, and such foaming agentsmay optionally be used to form at least a portion of the thermoplasticouter layer. The foamed layer may include, but is not limited to, athermoplastic with expand cells, and thermoplastic elastomers also knownas “TPE.” In yet another embodiment, a thermofoamed thermoplastic may beused to fill at least a portion of an interior space of the reinforcingmember, such as the center interior space or a peripheral interiorspace, where such spaces are originally hollow.

The thermoplastic outer layer may include a resin, and more preferably,the outer interior may be made of HDPE, PPE, another thermoplasticmaterial, or a combination of materials. Thus, the outer layerpreferably comprises as a thermoplastic, and may or may not furtherinclude additives, such as talc and/or Ca₂CO₃ that acts as a both afiller and strengthening material or reinforcement (e.g., crushedlimestone). In at least one embodiment of the invention, an additivesuch as talc is added to the thermoplastic to improve brittleness and/ormodulus characteristics. Embodiments include 0 to 45 percent by weighttalc, and more preferably, 20 to 40 percent by weight talc, and morepreferably yet, 25 to 35 percent by weight talc, and still morepreferably yet, 30 to 33 percent by weight talc. The extrusion processaligns and orients the talc to greatly increase modulus characteristics.

Practice of the invention may further include preparing the structuralreinforcing member, to include forming an aluminum alloy extrusion witha non-uniform surface, the surface extending a length of at least L. Themethod may further include forming an aluminum alloy with a non-uniformsurface that includes providing surface attributes that improve thebonding of the thermoplastic (or thermoplastic composites, such asamended HDPE) to the structural reinforcing member. The method mayfurther include preparing the structural reinforcing member to includeforming an aluminum alloy extrusion with a non-uniform surface, thesurface extending a length of at least L. Furthermore, the method mayinclude preparing the structural reinforcing member to include extrudingthe structural reinforcing member and adjusting its temperature bycooling.

As otherwise noted herein, and in accordance with various embodiments ofthe present invention, the exterior surface of the reinforcing membermay optionally comprise surficial features to assist in the mechanicalbonding of the surrounding resin with the exterior surface of thereinforcing member. By way of example and not limitation, the exteriorsurface of the reinforcing member may comprise one or more of a deboss,scarification and surface texturing. More particularly, a deboss of theexterior surface of the reinforcing member may comprise an indention inthe exterior surface. The indentation may be formed, for example, by amechanical tool impacting or pressing against the exterior surface ofthe reinforcing member to cause the indentation, wherein the indentationcauses a localized change in the planar surface of the exterior surfaceof the reinforcing member in the vicinity of the indentation. The debossis preferably a plurality of such indentations, wherein the debossextends along at least a portion of the longitudinal length of thereinforcing member.

In accordance with at least one embodiment, to form the glass-reinforcedpolyurethane interior material, liquid or molten glass is added to thetooling downstream of the extruded polyurethane to blend the twomaterials together. In accordance with various embodiments, theglass-reinforced polyurethane may be entrained with air or otherwisefoamed to provide a lighter material that still exhibits advantageousengineering properties. By way of example and not limitation, onepossible blend for the glass-reinforced polyurethane comprises 70% glassby weight and 30% polyurethane by weight. This blended materialcomprises the reinforcing member of various structural members asdescribed herein, and for example, can serve as a substitute materialfor an aluminum alloy reinforcing member. The glass-reinforcedpolyurethane is then fed through a crosshead die to the surroundingthermoplastic comprising, for example, HDPE or PP, with or withoutfillers of calcium carbonate or talc. Engineering property assessmentshave been made on this core, with values of 6.5-7.2 Mpsi modulus,simulating properties of aluminum. The glass-reinforced polyurethanecore/reinforcing member material also offers advantages over othermaterials, such as a metal alloy reinforcing core. More particularly,mechanical bonding between the reinforcing member and the surroundingthermoplastic is less significant of an issue because bonding betweenthe glass-reinforced polyurethane interior and the surroundingthermoplastic is achieved sufficiently through chemical bonding betweenthe two materials, that is, the reinforcing member and the surroundingthermoplastic.

By way of example and not limitation, for reinforcing members comprisinga metal, such as steel, aluminum or an aluminum alloy, the reinforcingmember may be heated or cooled to improve bonding of the thermoplasticmaterial around the reinforcing member. In addition, in at least oneembodiment, one or more streams of air or gas are can be directed at oneor more parts of the column, post or structural member duringmanufacturing to prevent the thermoplastic material from pulling awayfrom the reinforcing member. In at least one embodiment, one or morestreams of air or gas are thermally adjusted to promote controlledheating or cooling of the thermoplastic material against the reinforcingmember. In addition, in at least one embodiment of the invention, thedie used to form portions of the structural member are heated and/orcooled to control heating and/or cooling of the thermoplastic plasticmaterial and/or reinforcing member, thereby helping to control shrinkageand/or swelling of the thermoplastic material relative to thereinforcing member. An air pocket may be used in certain areas duringthe manufacturing process to avoid contraction of the thermoplasticmaterial away from the arms of the reinforcing member. Thus, during onepossible method of manufacture, as the reinforcing member enters die,such a crosshead thermoplastic extrusion die, the reinforcing member maybe either heated or cooled to assist in a more even cooling anddistribution of the thermoplastic material around the reinforcingmember. The die itself may also be either heated or cooled to furtherassist in a more even cooling and distribution of the thermoplasticmaterial around the reinforcing member. In addition, sonic vibration ofthe reinforcing member or the die may be applied to increasethermoplastic throughput, and thus increase overall production. Ingeneral, sonic vibration acts to keep the thermoplastic flowing and inliquid form and from reaching a solid condition prematurely. Inaddition, to assist even distribution of the thermoplastic in certainthicker sections, and air port providing air pressure may be added toassist in keeping the thermoplastic flow at more equal velocity andextend and maintain the contact with the reinforcing member.

To assist in the understanding of the present invention the followinglist of components and associated numbering found in the drawings isprovided herein:

Number Component 10 load bearing assembly 20, 50, 70, 90, 130, 180, 210structural member 14, 172 beam 18 screws 22 decking 23 first end ofstructural member 25 second end of structural member 26, 56, 76, 96,136, 188, 218 reinforcing member 28, 58, 78, 98, 138, 192, 222 channels24, 54, 74, 94, 134, 184, 214 thermoplastic casing/HDPE 30 interiorsurface of channels 32, 62, 82, 100, 148 faces of reinforcing member 34exterior of reinforcing member 36, 66, 86, 106, 108, 114, cross members122, 142, 146, 196, 226 38 octagonal pattern of reinforcing member 40,72, 92 interior of reinforcing member 42, 60, 110, 202 central interiorarea 44, 64, 84, 102, 104 peripheral interior areas 48 interior faces ofreinforcing member 68, 88  intermediate point of interior faces 80, 118center of structural member 100  lateral side of reinforcing member 164 bolt 168  nut Θ angle between cross members L Longitudinal length ofstructural member

FIG. 15A is a schematic side view of an embodiment of a window frame1500. As shown in FIG. 15A, the window frame 1500 includes framesmembers 1502, 1504, 1506, 1508 and 1510. In addition, a center mullion1512 is disposed between frame number 1502 and a structural support1516. The window frame 1500, that is illustrated in FIG. 15A, usesstructural supports for the frame members 1502-1510 and mullion 1512.The frame members can be constructed as described below and in themanner set forth above with respect to the beams disclosed in FIGS.1-14. Since the frame members 1502-1510 are structural members, they arecapable of providing a self-supporting window frame 1500. As shown inFIG. 15A, structural supports 1514, 1516, 1518 are aligned with framemember 1504, mullion 1512 and frame member 1508, respectively. In thisfashion, the frame member 1502 is supported by frame member 1504,mullion 1512 and frame member 1508 so that forces are transferred fromthe frame member 1502 to the structural supports 1514-1518.

FIG. 15B is a schematic illustration of an embodiment a window frame1520 with an attached header 1522. Header 1522 provides structuralsupport for the window frame 1520. Frame members 1524, 1526, 1528, 1530,1532 can be constructed as structural members or frame members that arenot structural members since header 1522 provides structural support.

FIG. 15C is a schematic illustration of another embodiment of a windowframe 1540. As shown in FIG. 15C, the window frame 1540 has framemembers 1542, 1544, 1546, 1548 and mullion 1550 that are not structuralmembers. Frame members 1542-1548 and mullion 1550 can be constructed asdisclosed in accordance with the disclosure relating to FIGS. 17-25below in a fashion that may or may not require that the frame members bestructural members. As shown in FIG. 15C, the frame members 1542-1548are joined together at 45 degree angles with frame connectors 1552.

FIG. 16 is a schematic illustration of the frame connectors 1600 thatcan be used to join the frame members such as frame member 1502 andframe member 1508 at a 45 degree angle. As shown in FIG. 16, connectors1602, 1604 comprise angle connectors that connect the two frame members1502, 1508 at a beveled 45 degree angle. Connectors 1602, 1604 comprisestandard connectors that are typically used to join frame members,together to form a window frame.

FIG. 17 is a schematic top view of an embodiment of frame member 1700that can be used in a window frame. As shown in FIG. 17, the framemember 1700 includes an internal reinforcing member 1702 that maycomprise an extruded metal frame that includes a number of lobes, suchas lobe 1704. The plastic material that is disposed within the lobes,such as lobe 1704, is married to and knitted with the hard plastic outerlayers 1710, 1712 and soft plastic layers 1714, 1716. The lobes, such aslobe 1704, help to hold the outer plastic layers 1710-1716 securely tothe reinforcing member 1702 so that the plastic coverings 1710-1716 donot become separated from the reinforcing member 1702. The plasticmaterial that is disposed within the lobes, such as lobe 1704, and theplastic layers 1710-1716 that are disposed on the outer surface of thereinforcing member 1702, are extruded in a two-step die as disclosed inmore detail below. The outer plastic layers 1710-1716 are extruded at ahigh temperature onto the reinforcing member 1702 and are allowed tocool in a relatively slow manner to ensure that there is no separationbetween the outer plastic layers 1710-1716 and the reinforcing member1702. As the outer plastic layers 1710-1716 cools, it shrinks andcreates a waist banding effect around the reinforcing member 1702 andsqueezes the reinforcing member 1702 in an inward direction. This waistbanding effect holds the outer plastic layers 1710-1716 securely on thereinforcing member 1702.

As also shown in FIG. 17, reinforcing member 1702 includes additionalcross members, such as cross member 1706, to provide additional supportto the reinforcing member 1702. The reinforcing member 1702 issurrounded by a plastic coating that includes hard plastic layers 1710,1712 and soft plastic layers 1714, 1716. The hard plastic materials1710, 1712 are married to and knitted with the soft plastic materials1714, 1716 to form a unitary enclosed structure that encloses thereinforcing member 1702. Soft plastic material 1716 provides a moistureseal with the adapter 1720 that holds the window insert 1718. Windowinsert 1718 may include a single pane window, double pane window, triplepane window, a photovoltaic collector or other device. Adapter 1720allows the window insert 1718 to be removed and replaced if the windowinsert 1718 becomes broken. Further, soft plastic 1714 provides amoisture seal between the frame member 1700 and any supporting structurefor the frame member 1700, such as the opening for a window frame. Ofcourse, hard plastic materials can be used in place of the soft plastics1714, 1716, as desired.

FIG. 18 is a schematic top view of an embodiment of a frame member 1800.As shown in FIG. 18, the frame member 1800 includes a reinforcing member1802 that has a number of lobes such as lobe 1804. As disclosed above,the plastic material that is extruded in the lobes, such as lobe 1804,is knitted with the outer plastic layers 1806, 1808, 1810, 1812. Crossmembers adjacent to the lobes, such as cross member 1820, add additionalstrength to the reinforcing member 1802. Again, waist banding occursthat tightly couples the outer plastic layers 1806-1812 to thereinforcing member 1802 to hold the outer plastic layer to thereinforcing member 1802. The waist banding effect, in conjunction withthe lobes, such as lobe 1804, securely holds the plastic coverings1806-1812 to the reinforcing member 1802. As also shown in FIG. 18, aflange 1824 is connected to the reinforcing member 1802, which iscovered by a soft plastic layer 1810 and a hard plastic layer 1812.Flange 1824 creates a U-shaped opening in which an adapter 1816 isdisposed that holds a window insert 1814. The adapter 1816 allows thewindow insert 1814 to be replaced without disassembling the windowframe. Soft plastic layer 1810 provides a moisture seal for the adapter1816. Of course, the soft plastic layer 1810 can be replaced by a hardplastic layer as desired. Olefin materials, such as HDPE orpolypropylene, can be used for the outer plastic layer. In addition, PVCcan also be used for the outer plastic layer. Materials, such as TPE orsimilar material, can be added to reduce the brittleness of the Olefinor PVC materials. In addition, additional TPE or similar material can beadded in greater percentages to produce the soft plastic material 1810that is disclosed in the various embodiments. FIG. 18 also illustratesthe manner in which a mounting block 1822 is disposed adjacent to theframe member 1800 for mounting the frame member 1800. Radius 1818illustrates the radius of the corners of the outer plastic coatings1806-1812.

FIG. 19 is a schematic top view of an embodiment of a mullion 1900. Asshown in FIG. 19, a reinforcing member 1902 is surrounded by a plasticlayer comprising hard plastic layers 1906, 1908 and soft plastic layers1910, 1912. Reinforcing member 1902 includes cross members, such ascross members 1914, 1915, that increase the strength of the reinforcingmember 1902. Mullion 1900 is disposed within the window frame andsupports two windows. As shown in FIG. 19, adapters 1916, 1918 supportwindow inserts 1920, 1922. Again, adapters 1916, 1918 provide astructure for replacing the window inserts 1920, 1922. Window inserts1920, 1922 can comprise any desired window insert, such as single pane,double pane, triple pane window or other devices such as photovoltaiccollectors. Because of the lightweight, durable and weather-resistantnature of the mullion 1900 and the frame member 1700 disclosed in FIG.17, and frame member 1800 disclosed in FIG. 18, the frame members andmullions disclosed are ideally adapted to hold photovoltaic devices andto provide other resistant coverings for photovoltaic devices. The softplastic layers 1910, 1912 provide a moisture seal around adapters 1916,1918, respectively. The soft plastic materials 1910, 1912 automaticallyprovide the moisture control and provide a convenient way of sealingwindow inserts 1920, 1922, as well as other devices such as photovoltaiccollectors. Of course, all of the embodiments disclosed herein can beused to support photovoltaic devices.

FIG. 20 is a schematic top view of another embodiment of a mullion 2000.As illustrated in FIG. 20, an outer plastic coating comprising hardplastic layers 2002, 2004 and soft plastic layers 2006, 2008 surroundthe reinforcing members 2010, 2012. A center support 2014 connects thereinforcing members 2010, 2012 and is also surrounded by soft plasticlayers 2006, 2008. The reinforcing members 2010, 2012 include a seriesof lobes, such as lobe 2016, that secure the outer plastic layer to thereinforcing members. Cross members, such as cross member 2018, addadditional structural support to the reinforcing members 2010, 2012. Thesoft plastic layers 2006, 2008 provide a moisture seal between themullion 2000 and the adapters 2024, 2026, respectively. Adapters 2024,2026 hold window inserts 2020, 2022, respectively. Adapters 2024, 2026provide a device for removing the window inserts 2020, 2022,respectively, if one of the window inserts 2020, 2022 becomes damaged.The embodiment disclosed in FIG. 20 can also be used for holdingphotovoltaic panels, as well as the embodiments disclosed in FIGS.21-25, and all of the embodiments disclosed herein.

FIG. 21 is a schematic top view of another embodiment of a mullion 2100.As shown in FIG. 21, the outer plastic coating comprises hard plasticlayers 2108, 2110 and soft plastic layers 2112, 2114. The outer plasticlayer substantially covers the reinforcing member 2102, as well as thecenter support 2118 and the end support 2116. In this fashion, theentire metal structure is substantially enclosed in the outer plasticlayer. The reinforcing member 2102 includes a number of lobes, such aslobe 2104, that are filled with the plastic material and knitted to theouter plastic layer to hold the outer plastic securely against thereinforcing member 2102. Cross member 2106, as well as other crossmembers, provide structural support for the reinforcing member 2102.Adapters 2124, 2126 are disposed in the U-shaped openings formed by thecenter support 2118 and end support 2116. Adapters 2124, 2126 engage theplastic layers 2112, 2114, respectively, which creates a moisture sealbetween the adapters 2124, 2126 and the mullion 2100. Adapter 2124 holdsthe window insert 2120 and provides a device for changing the windowinsert 2120. Similarly, adapter 2126 holds the window insert 2122 andprovides a device for changing the window insert 2122.

FIG. 22 is a schematic top view of another embodiment of a mullion 2200.As shown in FIG. 22, the mullion 2200 includes a reinforcing member 2202that is surrounded by an outer plastic layer that comprises hard plasticlayer 2204, soft plastic layer 2208 and soft plastic layer 2210. Theseplastic layers are knitted together to form a unitary outer plasticlayer that generates an inward waist banding force around thereinforcing member 2202 as the outer plastic layer cools. Reinforcingmember 2202 includes a number of lobes, such as lobe 2203, that hold theouter plastic layer securely to the reinforcing member 2202. Bracket2214 is held to the reinforcing member 2202 by way of a fastener 2216.Fastener 2216 can be a decorative screw, such as a metal screw, thatengages the metal of the reinforcing member 2202. Bracket 2214 comprisesa bracket support 2222 that is made of a metal material, such asaluminum, that is covered with hard plastic 2206 on the outer surfaceand a soft plastic 2212 on the interior surface. Window inserts 2218,2220 are held in place in U-shaped openings by the bracket 2214. All ofthe surfaces that are engaged by the window inserts 2218, 2220 are softplastic material that provides a moisture seal. Again, in thisembodiment, and all of the embodiments disclosed, the soft plasticmaterials can be replaced with hard plastic materials. The bracket 2214can be easily removed by loosening the fastener 2216 to replace thewindow inserts 2218, 2220.

FIG. 23 is a schematic top view of another embodiment of a mullion 2300.As shown in FIG. 23, a reinforcing member 2302 is surrounded by an outerplastic layer comprising hard plastic 2306, 2308 and soft plastics 2310,2312. The plastic layers 2306-2312 are knit together to form a solidouter plastic layer that shrinks and generates a force on thereinforcing member 2302 as the plastic outer layer cools. This assistsin holding the outer plastic layer to the reinforcing member 2302. Inaddition, lobes, such as lobe 2304, assist in holding the outer plasticlayer to the reinforcing member 2302. The mullion 2300 includesremovable brackets 2314, 2316. Fasteners 2322, 2324 hold brackets 2314,2316 to the reinforcing member 2302. Fasteners 2322, 2324 allow thebrackets 2314, 2316 to be removed to replace the window inserts 2334,2336. Bracket 2314 includes a bracket support 2318 that is surrounded bya hard plastic layer 2326 and a soft plastic layer 2330. Similarly,bracket 2316 includes a bracket support 2320 that is surrounded by ahard plastic layer 2328 and a soft plastic layer 2330. Window insert2334 is surrounded by the soft plastic layer 2312 and soft plastic layer2330 to provide a moisture seal. Similarly, window insert 2336 issurrounded by soft plastic layer 2310 and soft plastic layer 2332 toalso provide a moisture seal. Brackets 2314, 2316 can be removed andreplaced as needed to replace the window inserts 2334, 2336.

FIG. 24 is a schematic top view of another embodiment of a frame member2400. As shown in FIG. 24, frame member 2400 includes a reinforcingmember 2402 that is surrounded by a plastic layer that protects thereinforcing member 2402 from the environment and provides additionalsupport to the reinforcing member 2402. The outer plastic layer includesa hard plastic layer 2406 and a soft plastic layer 2408 that surroundthe reinforcing member 2402 and provide an inward waist banding forcethat holds the outer plastic layer to the reinforcing member 2402. Inaddition, there are a plurality of lobes, such as lobe 2404, that areformed in the reinforcing member 2402 that additionally help to hold theouter plastic layer to the reinforcing member 2402. The frame member2400 also includes a bracket 2410 that is secured to the reinforcingmember 2402 by a fastener 2412. Fastener 2412 can comprise a metal screwthat engages the metal of the reinforcing member 2402. Bracket 2410includes a metal bracket support 2414 that may also be made fromaluminum or other metal that is covered by a hard plastic material 2416and a soft plastic material 2418. The window insert 2420 engages thesoft plastic material 2408 and the soft plastic material 2418, whichprovide a moisture seal for the window insert 2420. The window insert2420 can be replaced by removing the bracket 2410 from the reinforcingmember 2402.

FIG. 25 is a schematic top view of another embodiment of a frame member2500. As shown in FIG. 25, reinforcing member 2502 is surrounded by anexterior plastic layer that comprises a hard plastic layer 2506 and asoft plastic layer 2508. Again, the hard plastic layer 2506 and the softplastic layer 2508 are knitted together as a unitary exterior plasticlayer that surrounds the reinforcing member 2502. As the exteriorplastic layer cools, it generates an inward waist banding force thatholds the outer plastic layer to the reinforcing member 2502. Aplurality of lobes, such as lobes 2504 formed in the reinforcing member2502, captures and holds the outer plastic layer securely to thereinforcing member 2502. The frame member 2500 also includes a removablebracket 2510. The removable bracket 2510 includes a metal bracketsupport 2512 that is surrounded by a soft plastic layer 2514 and a hardplastic layer 2516. Fastener 2518 engages the reinforcing member 2502and securely holds the bracket 2510 to the reinforcing member 2502.Window insert 2520 engages the soft plastic layer 2508 and the softplastic layer 2514 so that a moisture seal is created between windowinsert 2520 and the soft plastic layers 2508, 2514. The window insert2520 can easily be removed and replaced by removing fastener 2518.

Hence, frame members and mullions have been disclosed that can be eitherstructural supports or non-structural supports that hold window insertsin a window frame. In addition, the various embodiments can also be usedto hold photovoltaic panels in a frame. The frame members include areinforcing member that is protected by an encapsulated outer plasticlayer that is held securely to the metal reinforcing member as a resultof the waist banding effect of the outer plastic layer that contracts asit cools and completely surrounds the metal reinforcing member. Also,lobes are formed in the metal reinforcing member that holds the outerplastic layer to the metal reinforcing member. In addition, removablebrackets or adapters can be used to replace window units or photovoltaicpanels. Soft plastic material can be formed in the areas in which thewindow insert or photovoltaic panel engages the frame member or mullionto create a moisture seal.

FIG. 26 is a schematic top view of another embodiment of a frame member2600. As shown in FIG. 26, the frame member 2600 includes a reinforcingmember 2602 that can be made from any desired material, such asaluminum, steel, etc. The reinforcing member 2602 is formed to provide aplurality of lobes, such as lobes 2604. The lobes encapsulate a plasticmaterial 2610 that is extruded in the first stage of an extrudingdevice, as disclosed below. The outer plastic layer 2608 is extruded ina second stage of an extruding device and knits with the plastic 2610 inthe lobes. The outer plastic layer 2608 and the plastic 2610 in thelobes knit together to form a unitary structure. The plastic 2610 in thelobes helps to secure the outer plastic layer 2608 to the reinforcingmember 2602. In addition, as the outer plastic layer 2608 cools, itcontracts and generates an inward waist banding force that secures theouter plastic layer 2608 to the reinforcing member 2602. The framemember 2600 also includes a flange 2614 that supports the window insert2620. A removable bracket 2612 secures the other side of the windowinsert 2620 and holds the window insert 2620 securely to the framemember 2600. If the window insert 2620 is damaged, the removable bracket2612 can be removed to remove the window insert 2620. A tab 2618 is usedto secure the frame member 2600 to a stud 2616 that holds the framemember 2600 to the supporting structure around the frame member 2600.

FIG. 27 is a schematic top view of another embodiment of a frame member2700. As shown in FIG. 27, the frame member 2700 includes a sash member2702 and a frame member 2704. Frame member 2704 includes a decorativemolding 2706 that has a series of structural members 2728 that allowsome flexion of the decorative molding 2706. The decorative molding 2706extends over the exterior wall 2732 to provide a decorative piece thatcovers the exterior wall 2732. Frame member 2704 includes a reinforcingmember 2708 that includes a plurality of lobes, such as lobe 2714.Plastic 2730 is extruded in a first stage of an extrusion device intothe lobes of the frame member 2704. Similarly, lobes in the sash member2702, such as lobe 2712, are also filled with extruded plastic in afirst stage of a two-stage crosshead die, as explained in more detailbelow. An outer plastic layer 2722 is extruded around the reinforcingmember 2708 in a second stage of a two-stage crosshead die. Again, theouter plastic layer 2722 is held to the reinforcing member 2708 by thewaist banding effect, as the plastic layer 2722 contracts duringcooling. The plastic 2730 in the lobes also holds the plastic layer 2722to the reinforcing member 2708. Sash member 2702 is constructed in asimilar manner so that the plastic layer 2724 is securely held to thereinforcing member 2710. Plates 2716, 2718, 2720 add additionalstructure to the sash member 2702. Window insert 2720 is disposedbetween the flange 2734 of the sash member 2702 and the removablebracket 2726. The removable bracket 2726 can be removed to replace thewindow insert 2620 if it becomes damaged.

FIG. 28 is a schematic diagram of an embodiment of a two-stage crossheaddie 2800. As shown in FIG. 28, a reinforcing member formation device2822 may receive a roll of flat metal roll material, such as aluminum oraluminum alloy. The reinforcing member formation device 2822 bends theroll sheet material into the proper shape for the reinforcing member.The reinforcing member 2828 is then advanced to the metal working device2826 that works the metal of the reinforcing member 2828. For example,the metal working device may form holes, divots, scarification and/orindentations in the reinforcing member, as more fully disclosed withrespect to FIGS. 48 and 49, below. A cooling tank 2824 may also be usedto cool the reinforcing member prior to insertion into the crossheaddie. The metal working device 2826, the reinforcing member formationdevice 2822 and the cooling tank 2824 are all optional devices. Areinforcing member 2806 can be delivered to the two stage crosshead dieconfiguration device 2800 ready for application of the resin withoutgoing through the process of forming the reinforcing device on locationat the extrusion die site. As further shown in FIG. 28, the reinforcingmember 2806 has a cross-sectional shape, such as the various shapesshown in the various figures disclosed herein. Reinforcing member 2806is fed into the die plates 2808. The entrance plate 2810 has an openingthat corresponds to the cross-sectional shape of the reinforcing member2806 and prevents the backflow of plastic out of the entrance plate2810. Extruder 2802 melts the plastic material and forces the plasticmaterial at high pressure into the adapter 2804. A series of connectingchannels extend through the die plates 2808 from the adapter 2804 to thevarious die plates comprising the stage one die plates 2812 and thestage two die plates 2814. The plastic material may be a subfractionalmelt HDPE or polypropylene material. Alternatively, PVC may be used, orother materials, as disclosed above. When a subfractional melt HDPE isused, it has low viscosity, so that the plastic must be extruded intothe lobes in the stage one plates 2812 and then subsequently extruded,as the outer coating layer in the stage two plates 2814. Exit plate 2816prevents the flow of plastic out of the exit of the die plates 2808. Thecoated reinforcing member, i.e., the structural member 2818, then exitsfrom the die plates 2808 and travels through a cooling tank 2820. Thestructural member 2818 exits the die plates 2808 at a temperature in therange of 385° to 425° F. One or more cooling tanks or cooling watersprays may be used to cool the coated structural member 2818. The rateat which the structural member 2818 is cooled has an effect on thestress that is created in the thermoplastic layer. If the structuralmember 2818 is cooled too fast, stress relaxation will be exacerbated.In other words, to prevent separation of the outer plastic layer fromthe reinforcing member, it is important that the structural member 2818is allowed to cool in air slowly over several days or weeks.

FIGS. 29-47 illustrate additional structural members. These structuralmembers may be used in the manner similar to the manner in whichstandard dimensional lumber is used in construction, such asconstruction of buildings or other types of structures such as decks,docks and other structures that are exposed to weather, moisture and/orsaltwater. These members may comprise beams, posts, columns, I-joists,rim joists, trusses or portions of trusses and other types of structuralmembers commonly used in construction. The reinforcing membersthroughout this application may comprise a metal or metal alloymaterial. For example, the reinforcing members may comprise an aluminumalloy material. Alternatively, the reinforcing members may comprisefiber glass, steel, carbon fiber, other types of fiber structures or anyother type of reinforcing material that functions as a reinforcingelement within the structural members illustrated.

The thermoplastic outer layers illustrated in all of the embodimentsdisclosed in this application may comprise any of a variety of types ofthermoplastic materials which may include various types of fillers, suchas talc, calcium carbonate or similar materials that increase thestructural strength of the thermoplastic outer layers.

FIG. 29 is a schematic perspective view of one embodiment of astructural member 2900 that is formed in the shape of an I-joist. TheI-joist includes a reinforcing member 2902 which is covered by athermoplastic outer layer 2904. FIG. 29 illustrates a portion of thethermoplastic outer layer 2904 removed from the reinforcing member 2902so that portions of the reinforcing member 2902 can be viewed. Thereinforcing member 2902 is formed to have two hollow flanges 2906, 2908that are joined together by web 2920. The thermoplastic outer layer 2904is extruded over the reinforcing member 2902, using a crosshead dieextruder, such as illustrated in FIG. 28. The crosshead die extruderthat extrudes thermoplastic material on the outer layer of theembodiment of FIG. 29, as well as all of the different embodimentsillustrated in FIGS. 29 through 46, may use a single stage die. Theembodiment of FIG. 47 may use a two-stage die.

Flanges 2906, 2908 of the structural member 2900, illustrated in FIG.29, are formed with openings 2910, 2912, respectively, which reduces theoverall weight of the structural member 2900. In addition, flanges 2906,2908 provide additional strength to the structural member 2900 becauseof the structural features of the flanges 2906, 2908, especially whenreinforcing member 2902 is covered with a thermoplastic outer layer2904. Flanges 2906, 2908 define a longitudinal axis 2922 of thestructural member 2900. Each of the structural members illustrated inFIGS. 29-46 may use a thermoplastic material that can include one ormore fillers, such as calcium carbonate and/or talc. Talc can beincluded in amounts up to 50 percent, but preferably up to approximately40 percent, to add strength to the plastic material. When thethermoplastic material is co-extruded onto the reinforcing member 2902,significant increases in the modulus of the elasticity occur. It isbelieved that the talc becomes oriented during the process of extrusionwhich results in these increases in the modulus of the elasticity.

As also shown in FIG. 29, a plurality of holes, such as holes 2914,2916, are placed throughout the reinforcing member 2902. Extrusion ofthe thermoplastic outer layer 2904 over the reinforcing member 2902causes the thermoplastic outer layer 2904 to penetrate the holes, suchas 2914, 2916 that cause the thermoplastic outer layer 2904 to penetrateand securely attach to the structural reinforcing member 2902. Further,indentation 2918 also assists in securely attaching the thermoplasticouter layer 2904 to the reinforcing member 2902. In addition, when thethermoplastic outer layer 2904 cools, it shrinks and causes a waistbanding effect that squeezes the thermoplastic layer 2904 onto thereinforcing member 2902 to further secure the thermoplastic outer layer2904 to the reinforcing member 2902.

FIG. 30 is a side elevation view of the structural member 2900 that isillustrated in FIG. 29. FIG. 30 illustrates the holes that are formed inthe reinforcing member 2902, such as holes 2916, 3002, as well asindentation 2918. Again, these holes assist in securing thethermoplastic outer layer 2904 to the reinforcing member 2902. Thespacing of the holes also assists in distributing the stress of thethermoplastic outer layer 2904 over the surface of the structural member2900 to prevent cracking. Although these holes are shown as beingsubstantially circular in shape, these holes may take other shapes andcan be made of different sizes. The holes can be formed using a stampingor contacting technique using stamping rollers or other stamping devicesprior to formation of the structural shape illustrated in FIG. 29. Forexample, the reinforcing member 2902 may be provided in a roll sheet ofan aluminum alloy material that is unrolled and sent through a stampingmachine to form the openings illustrated in FIGS. 29 and 30. The stampedmetal sheet can then be fed through a forming device to form the shapeof the reinforcing member 2902 that is illustrated in FIG. 29.Alternatively, holes may be formed after the reinforcing member isformed using a hole punching device similar to the debossing devicesillustrated in FIG. 48. In addition, the metal material that forms thereinforcing member 2902 can also be treated in other ways as disclosedbelow, such as scarification of the material, as shown in FIG. 49,and/or debossing of the metal, as illustrated in FIG. 48.

FIG. 31 is an end view of the structural member 2900 that is illustratedin FIGS. 29 and 30. As shown in FIG. 31, the reinforcing member 2902 isencapsulated by the thermoplastic outer layer 2904. As indicated above,the encapsulation of the reinforcing member 2902 by the thermoplasticlayer 2904 in the holes, such as holes 2916, cause the thermoplasticouter layer 2904 to squeeze the reinforcing member 2902 as a result ofshrinkage of the thermoplastic material during cooling which causes awaist banding effect. As a result, the thermoplastic layer is securelyattached to the reinforcing member 2902. Flange 2906 and flange 2908 areconnected by the web 3102. The reinforcing member 2902 is formed so thatthere is an overlapping portion 3104, 3106 in flanges 2906, 2908,respectively.

FIG. 32 is a perspective view of the embodiment of the reinforcingmember 2902 that is illustrated in FIGS. 29-31. Again, the reinforcingmember 2902 has two flanges 2906, 2908 that are connected by a web 3102.Both the flanges 2906, 2908, as well as the web 3102, have a pluralityof holes that secure the thermoplastic layer to the reinforcing member2902. The holes in the web 3102 allow thermoplastic material on bothsides of the web to communicate through the web 3102 and be securelyheld to the web as the thermoplastic material cools and shrinks. Thethermoplastic material 2904 that is extruded over the flanges 2906, 2908seeps into the openings 2910, 2912 (FIG. 29) through the holes in theflanges, such as holes 3002 (FIG. 30), so as to hook or secure thethermoplastic layer 2904 to the interior portions of the flanges 2906,2908, that further secures the thermoplastic layer 2904 to the flanges2906, 2908. FIG. 32 also illustrates indentations 2918, 3202 and 3204that are formed transverse to the longitudinal axis 2922 of thereinforcing member 2902.

FIG. 33 is an end view of the structural member 2900. As shown in FIG.33, openings 2910, 2912 can either be empty or filled with a material,such as foam or other reinforcing material. Overlaps 3104, 3106 areencapsulated within the thermoplastic material 2904 and help to securethe overlapped areas of the reinforcing member 2902.

FIG. 34 is an end view of the reinforcing member 2902. As shown in FIG.34, the overlapped area 3104 is placed at the transition between theflange 2906 and the web 2920. Similarly, the overlap area 3106 is placedat the transition between the flange 2912 and the web 2920. Placing theoverlaps 3104, 3106 in these locations provides additional strength tothe reinforcing member 2902. Further, openings can be placed through theoverlap areas. For example, overlap area 3104 may have an opening 3402.The opening 3402 allows the thermoplastic layer 2904 to communicatethrough the opening 3402 and help to secure the overlap 3104 to the web2920 and further strengthen the flange 2906. Similarly, opening 3404 maybe placed in overlap 3106 to strengthen flange 2912. A series ofopenings, such as openings 3402, 3404, may be placed along the length ofthe reinforcing member 2902 in the overlap areas.

The reinforcing member 2902, illustrated in FIG. 34, may comprise analuminum alloy that has a weight of between approximately 0.75 and 1.25pounds per foot of longitudinal length. Other embodiments use analuminum allow having a weight of approximately 0.90 to 1.15 pounds perfoot, or 0.94 to 1.1 pounds per foot. The reinforcing member 2902 mayhave a cross-sectional area of between 1.3 and 1.5 square inches. Thesevalues are considered to be examples only and various sizes and weightsof the reinforcing member can be employed as desired. Various weights,sizes and lengths can be used as a substitute for dimensional lumber asshown in FIG. 1.

FIG. 35 illustrates another embodiment of a structural member 3500. Asshown in FIG. 35, a reinforcing member 3504 is formed in a rectangularshape and has an overlapping area 3506. A thermoplastic outer layer 3502is extruded over the reinforcing member 3504 in the manner describedabove. As the thermoplastic outer layer 3502 cools, it shrinks andcauses a waist banding effect that squeezes the thermoplastic outerlayer 3502 around the reinforcing member 3504. The structural member3500 can be used in place of various sizes of dimensional lumber. Forexample, structural member 3500 can be used in place of 2 inch×10 inchdimensional lumber. In that instance, the thermoplastic outer layer 3502may have a thickness of between 0.12 to 0.25 inches. Other ranges ofthicknesses include 0.125 to 0.20 inches or approximately 0.1875 inches,which is 3/16 of an inch. In one embodiment, the reinforcing member 3504may comprise an aluminum alloying having a thickness of betweenapproximately 0.05 to 0.2 inches. Other embodiments include thicknessesof approximately 0.075 to 0.15 or 0.1 inches. The interior portion 3510that is inside of the reinforcing member 3504 may be empty, partiallyfilled or filled with foam or other reinforcing structural material toassist in increasing the rigidity of the structural member 3500.

FIG. 36 is a schematic end view of the reinforcing member 3504 that isillustrated in FIG. 35. As shown in FIG. 36, the overlap area 3506 isalong one of the short ends of the reinforcing member 3504. Of course,the overlapping area can be formed on any edge of the reinforcing member3504, although overlapping of a short end of the reinforcing member 3504provides the greatest strength and reduces the material cost. As alsoshown in FIG. 36, holes 3602, 3604 can be formed in the reinforcingmember 3504 in the overlap area 3506 that assists in holding thereinforcing member 3504 together and securely attaching thethermoplastic layer 3502 (FIG. 35) to the reinforcing member 3504.

FIG. 37 is a schematic perspective view of the structural member 3500that is illustrated in FIGS. 35 and 36. As shown in FIG. 37, astructural member has a thermoplastic outer layer 3502 that covers thereinforcing member 3504. Reinforcing member 3504 has a plurality ofholes, such as hole 3702 that assists in holding the thermoplastic outerlayer 3502 to the reinforcing member 3504. In addition, an indentation3704 is formed in the reinforcing member 3504 to further assist inholding the thermoplastic outer layer 3502 to the reinforcing member3504.

FIG. 38 is a schematic end view of another embodiment of structuralmember 3800. As shown in FIG. 38, a thermoplastic outer layer 3502surrounds a reinforcing member 3804. The reinforcing member 3804 isdivided into a series of segments by segment arms, such as segment arms3806, 3810, 3812, 3814. Each of the segment arms is held in place by acurved support. For example, segment arm 3806 is held in a curvedsupport 3808 that is formed into the reinforcing member 3804. In thismanner, the segment arms 3806-3814 are secured in the structural member3800. The waist banding effect that is caused when the thermoplasticouter layer 3802 cools and shrinks which forces the segment arms intothe curved supports.

FIG. 39 is a schematic end view of the reinforcing member 3804illustrated in FIG. 38. As shown in FIG. 39, the segment arm 3806 isplaced in the curved support 3808 and is held in a secure position bythe reinforcing member 3804. The segment arms 3806-3814 provideadditional support to the reinforcing member 3804.

FIG. 40 is a schematic isometric view of another embodiment of astructural member 4000. As shown in FIG. 40, the thermoplastic outerlayer 4002 surrounds the reinforcing member 4004. Indentations, such asindentation 4006, are formed in the reinforcing member 4004 to hold thethermoplastic outer layer 4002 to the reinforcing member 4004. Inaddition, a plurality of holes are also formed in the reinforcing member4004, such as hole 4008, which also assists in holding the thermoplasticouter layer 4002 to the reinforcing member 4004.

FIG. 41 is a schematic end view of the structural member 4000 that isillustrated in FIG. 40. As shown in FIG. 41, the thermoplastic outerlayer 4002 is extruded over the reinforcing member 4004. Since thethermoplastic outer layer 4002 is hot and somewhat fluid during theextrusion process, the thermoplastic outer layer 4002 seeps in theapertures 4012, 4014, 4016 to create lobes or buttons 4006, 4008, 4010,respectively. The lobes 4006-4010 hold the thermoplastic outer layer4002 securely to the reinforcing member 4004. In addition, the waistbanding effect, that occurs as the thermoplastic outer layer 4002 cools,also holds the thermoplastic outer layer 4002 to the reinforcing member4004. The reinforcing member 4004 has an overlap area 4018 that isadjacent to one of the corners of the triangular shape of the structuralmember 4000. As disclosed above, the overlap area 4018 may also have anaperture or opening that assists in holding the reinforcing member 4004together in the overlap area 4012.

FIG. 42 is a schematic perspective view of another embodiment of astructural member 4200. As shown in FIG. 42, the structural member 4200has a cylindrical shape and can be used as a round post. Thermoplasticouter layer 4202 is extruded onto the outer surface of reinforcingmember 4204. Indentations, such as indentation 4206, and holes, such ashole 4208, assist in holding the thermoplastic outer layer 4202 to thereinforcing member 4204. Again, as the thermoplastic outer layer 4202cools, it shrinks and creates a waist banding effect around thereinforcing member 4204.

FIG. 43 is a cut-away view of the structural member 4200 illustrated inFIG. 42. As shown in FIG. 43, the thermoplastic outer layer 4202 isco-extruded around the reinforcing member 4204 in a hot, semi-liquidstate which causes the thermoplastic material to seep within theapertures 4220, 4222, 4224, 4226 to form buttons 4212, 4214, 4216, 4218,respectively. The lobes 4212-4218 function to hold the thermoplasticouter layer 4202 to the reinforcing member 4204 in a secure manner. Inaddition, as the thermoplastic outer layer 4202 cools, it shrinks andcauses a waist banding effect around the reinforcing member 4204.Reinforcing member 4204 is joined together by a weld 4210 rather thanbeing overlapped as shown in other embodiments.

FIG. 44 is a schematic perspective view of another embodiment of astructural member 4400 that has a substantially square cross section. Asshown in FIG. 44, the thermoplastic outer layer 4402 is extruded aroundthe reinforcing member 4404. The thermoplastic outer layer 4402 is ahot, semi-liquid state and forms a plurality of lobes, such as lobe4408, when it seeps through the holes, such as hole 4406. The lobesassist in holding the thermoplastic outer layer 4402 to the reinforcingmember 4404. In addition, when the thermoplastic outer layer 4402 cools,it shrinks and causes a waist banding effect that causes thethermoplastic outer layer 4402 to squeeze the reinforcing member 4404and hold the thermoplastic outer layer 4402 to the reinforcing member4404.

FIG. 45 is a schematic cross-sectional view of another embodiment of astructural member 4500. As shown in FIG. 45, a thermoplastic outer layer4502 surrounds a reinforcing member 4504. Reinforcing member 4504 has aplurality of apertures, such as aperture 4506. When the thermoplasticouter layer 4502 is extruded over the reinforcing member 4504, it is ina hot, semi-liquid state so as to cause the thermoplastic material toflow through the apertures, such as aperture 4506, and form lobes, suchas lobe 4508, on the interior portion of the reinforcing member 4504.The lobes, such as lobe 4508, help to anchor or secure the thermoplasticouter layer 4502 to the reinforcing member 4504.

FIG. 46 is a partial schematic cross-sectional view of a structuralmember 4600. As shown in FIG. 46, a thermoplastic outer layer 4602 isextruded in a hot state over the reinforcing member 4604 and flowsthrough aperture 4606 to form lobe 4608. Lobe 4608 is affected bygravity and secures to the bottom portion of the aperture 4606. Lobe4608 helps to anchor the thermoplastic outer layer 4602 to thereinforcing member 4604.

FIG. 47 is a schematic end view of a structural member 4700. As shown inFIG. 47, a first thermoplastic layer 4702 is extruded over thereinforcing member 4706. Subsequently, a second thermoplastic layer 4704is extruded over the first thermoplastic layer 4702. The firstthermoplastic layer 4702 may have different properties than the secondthermoplastic layer 4704. For example, first thermoplastic layer 4702may have properties that allow thermoplastic layer 4702 to adhere to thereinforcing member 4706. Second thermoplastic layer 4704 may includecolor or other properties that are desirable for an outer covering. Forexample, second thermoplastic layer 4704 may comprise PVC which can havea bright white color that is not achievable in many thermoplastics. Ofcourse, other materials can be used that have other colors and surfacetextures. Layers 4702, 4704 can be extruded using a two-stage crossheaddie, such as two-stage crosshead die 2800, illustrated in FIG. 28.

FIG. 48 is a schematic perspective view of a debossing device 4800. Asshown in FIG. 48, a structural member 4802 is fed into the input of thedebossing device 4800. The debossing device 4800 has a series ofdebossing wheels 4806, 4808, 4814, 4816 that create debossing (divots)4818, 4820 on the structural member 4802. Other debossing wheels may belocated to deboss other sides of the structural member 4802. Motor 4804drives the debossing wheels which are coupled together by gears 4810,4812. The debossing process creates divots 4818, 4820 in the structuralmember 4802 that do not penetrate the walls of the structural member4802. The debossing provides surface structure which allows thethermoplastic material to more securely attach to the surface of thestructural member 4802. The size and spacing of the debossing assist indistributing stress of the thermoplastic layer over the surface of thestructural member 4802 to prevent cracking of the thermoplasticmaterial. Alternatively, the debossing wheels 4806, 4808, 4814, 4816 canbe replaced with wheels that form holes in the structural member 4802.

FIG. 49 is a schematic perspective view of a scarification device 4900.As shown in FIG. 49, the scarification device 4900 includes sandingdevices having sanding belts 4904, 4906. The sanding belts 4904, 4906engage two opposing sides of the structural member 4902 to sand twosurfaces of the structural member 4902. Other surfaces can also besanded with additional belts. The sanding belts 4904, 4906 createscarifications 4910 on the surface of the structural member 4902 thatassist in attaching the thermoplastic material to the surface of thestructural member 4902. Of course, both the process of scarificationillustrated in FIG. 49 as well as the process of debossing asillustrated in FIG. 48 can be used to increase the adhesion of thethermoplastic material to the surface of the structural members.

FIG. 50 is a flow diagram of one embodiment of a process for forming astructural member. As shown in FIG. 50, at step 5002 a reinforcingmember is extruded from a die. In that regard, the reinforcing member isshaped in the desired shape using an extrusion process. At step 5004,the extruded reinforcing member is transported to a separate facilityfor adding an outer layer of resin. At step 5006, apertures, debossing,scarification and/or indentations are formed in the reinforcing member.This is more fully disclosed in FIGS. 48 and 49. At step 5008, thereinforcing member is positioned at the backend of a crosshead die forextrusion of an outer layer of resin, as more fully disclosed withrespect to the description of FIG. 28. In several of the embodimentsdisclosed herein, a two-stage crosshead die configuration is used, sothat two layers of thermoplastic material are extruded onto areinforcing member. In several of the other embodiments, only a singlelayer of thermoplastic material is required. In these embodiments, onlya single stage crosshead die extruder is required that is similar tothat shown in FIG. 28, except that it has only a single stage. At step5010, the reinforcing member is advanced through the crosshead die sothat the thermoplastic layer is extruded over the reinforcing member toform the structural member. At step 5012, the structural member iscooled as illustrated in FIG. 28 by cooling tank 2820. At step 5014, thestructural member is cut to the desired longitudinal lengths, asillustrated in FIG. 28, by cutter 2826.

FIG. 51 is a schematic block diagram of an alternative process forforming a structural member. At step 5102, a roll of material, such as aroll of aluminum alloy metal, is received to form a reinforcing member.At step 5104, the roll material is bent to form the shape of thereinforcing member. The reinforcing member formation device 2822 bendsthe metal to form the shape of the reinforcing member. Apertures,debossing, scarification and/or indentations can be formed in the metaleither before or after the sheet roll has been bent into the shape ofthe reinforcing member. Metal working device 2826, illustrated in FIG.28, can perform the processes of forming apertures, debossing,scarification and/or indentations. At step 5106, the reinforcing memberis positioned at the back of the die, as illustrated in FIG. 28, toreceive the outer layer of resin using the extrusion process disclosedwith respect to FIG. 28. At step 5108, the reinforcing member isadvanced through the crosshead die plates, as disclosed in FIG. 28, andthe outer thermoplastic layer is applied to the reinforcing member. Atstep 5110, the structural member 2818 is cooled in cooling tank 2820, asalso illustrated in FIG. 28. At step 5112, the structural member is cutto the desired longitudinal lengths using a cutter 2826, as disclosed inFIG. 28.

The foregoing description of the invention has been presented forpurposes of illustration and description. It is not intended to beexhaustive or to limit the invention to the precise form disclosed, andother modifications and variations may be possible in light of the aboveteachings. The embodiment was chosen and described in order to bestexplain the principles of the invention and its practical application tothereby enable others skilled in the art to best utilize the inventionin various embodiments and various modifications as are suited to theparticular use contemplated. It is intended that the appended claims beconstrued to include other alternative embodiments of the inventionexcept insofar as limited by the prior art.

What is claimed is:
 1. A method of making a frame structure comprising:providing a reinforcing member having an outer surface and at least aportion having a substantially hollow interior; forming a plurality oflobes in said reinforcing member having an interior lobe size that islarger than a lobe waist opening; extruding a first plastic layer intosaid plurality of lobes until said plastic extends into said lobe waistopening; extruding an exterior plastic layer over substantially all ofsaid outer surface of said reinforcing member while said first plasticlayer is sufficiently hot to knit to said exterior plastic layer to forma substantially unitary plastic coating structure comprising said firstplastic layer and said exterior plastic layer that is securely held tosaid reinforcing member by said first plastic layer that is disposed insaid lobes, said exterior plastic layer creating an inward force on saidreinforcing member as said exterior plastic layer cools and contracts tofurther hold said exterior plastic layer securely to said reinforcingmember.
 2. The method of claim 1 further comprising: holding an insertin a recess formed in said metal reinforcing member that is covered bysaid substantially unitary plastic coating structure to secure saidinsert to said frame structure.
 3. The method of claim 2 wherein saidinsert comprises a window insert.
 4. The method of claim 2 wherein saidinsert comprises a photovoltaic detector.